General information

About the Installation Manual

This publication is intended as a guide for the installation of the Electronic Vessel Control system (EVC) for Volvo Penta IPS 350, 400, 450, 500 and 600. The publication is not comprehensive and does not cover every possible installation, but is to be regarded as recommendations and guidelines applying to Volvo Penta standards. Detailed Installation Instructions are included in most of the accessory kits.

These recommendations are the result of many years of practical experience of installations from all over the world. Departures from recommended procedures etc. can be necessary or desirable, however, in which case the Volvo Penta organization will be glad to offer assistance in finding a solution for your particular installation.

It is the sole responsibility of the installer to ensure that the installation work is carried out in a satisfactory manner, it is operationally in good order, the approved materials and accessories are used and the installation meets all applicable rules and regulations. This Installation Manual has been published for professionals and qualified personnel. It is therefore assumed that persons using this book have basic knowledge of marine propulsion systems and are able to carry out related mechanical and electrical work.

Installation of electrical systems shall only be carried out by a professional boat electrician. Only components, cables, connections etc, delivered or approved by the manufacturer may be used. The manufacturer will accept no responsibility what so ever if this requirement is ignored.

Volvo Penta continuously upgrades its products and reserves the right to make changes. All the information contained in this manual is based on product data available at the time of print. Notification of any important modifications to the product causing changes to installation methods after this date will be made in Service Bulletins.

Plan installations with care

Great care must be taken in the installation of engines and their components if they are to operate perfectly. Always make sure that the correct specifications, drawings and any other data are available before starting work. This will allow for correct planning and installation right from the start.

Plan the engine room so that it is easy to carry out routine service operations involving the replacement of components. Compare the engine Service Manual with the original drawings showing the dimensions. It is very important when installing engines that no dirt or other foreign matter gets into the fuel, cooling, intake or turbocharger systems, as this can lead to faults or engine seizure. For this reason the systems must be sealed. Clean supply lines and hoses before connecting them to the engine. Only remove protective engine plugs when making a connection to an external system.

Important

Never use any kind of grease in the EVC connectors.

Never cut or modify the Volvo Penta EVC cable harnesses. For extra power supply use the Volvo Penta relay for accessories.

Refer to the Relay for external accessories section.

Certified engines

The manufacturer of engines certified for national and local environmental legislation (Lake Constance for example) pledges that this legislation is met by both new and currently operational engines. The product must compare with the example approved for certification purposes. So that Volvo Penta, as a manufacturer, can pledge that currently operational engines meet environmental regulations, the following must be observed during installation:

• Servicing of ignition, timing and fuel injection systems (gasoline) or injector pumps, pump settings and injectors (diesel) must always be carried out by an authorised Volvo Penta workshop.

• The engine must not be modified in any way except with accessories and service kits developed for this engine by Volvo Penta.

• Installation of exhaust pipes and air intake ducts for the engine compartment (ventilation ducts) must be carefully planned as its design may affect exhaust emissions.

• Seals may only be broken by authorised personnel.

IMPORTANT! Use only Volvo Penta Genuine Parts.

Using non-genuine parts will mean that Volvo Penta will no longer take responsibility for the engine meeting the certified design. All damage and costs caused by the use of nongenuine replacement parts will not be covered by Volvo Penta.

Seaworthiness

It is the boat builder’s duty to check that the security requirements apply to the market in which the boat is sold. In the USA for example, these are the US Federal Regulations for pleasure boats described in Title 46. The requirements described below apply to the EU principles. For information and detailed descriptions of the safety requirements that apply to other markets, contact the authority for the country concerned.

As of June 6 998, pleasure boats and certain associated equipment marketed and used within the EU must bear CE labels to confirm that they meet the safety requirements stipulated by the European Parliament and Council of Europe’s directive for pleasure boats. The normative requirements can be found in the standards drawn up to support the directive’s objective of uniform safety requirements for pleasure boats in EU countries.

Certificates that grant the right for CE label use and confirm that boats and equipment meet safety requirements are issued by approved notified bodies. In many Member States the classification societies have become the notified bodies for pleasure boats, e.g. Lloyd’s Register, Bureau Veritas, Registro Italiano Navale, Germanischer Lloyd, etc.

In many cases completely new institutions have been approved as notified bodies. The directive also allows boat builders and component manufacturers to issue assurances of compliance with the requirements of the directive. This requires the manufacturer to store the prescribed product documentation in a place that is accessible to the monitoring authority for at least ten years after the last product is produced.

Life boats and boats for commercial activities are approved by classification societies or by the navigation authority for the boat’s registered country.

Joint liability

Each engine consists of many components working together. One component deviating from its technical specification can cause a dramatic increase in the environmental impact of an engine. It is therefore vital that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used. Certain systems e.g. components in the fuel system may require special expertise and special test equipment. Some components are sealed at the factory for environmental reasons. No work should be carried out on sealed components except by authorised personnel.

Remember that most chemical products damage the environment if used incorrectly. Volvo Penta recommends the use of biodegradable degreasing agents for cleaning engine components, unless otherwise indicated in a Workshop Manual. Take special care when working on board boats to ensure that oil and waste are taken for destruction and not accidentally pumped into the environment with bilgewater.

Conversion factors

Metric to U.S. or IMP. conversion factors: U.S. or IMP. to metric conversion factors: To

) All hp figures stated in the catalogue are metric.